Magnetic Composite Body With Oxide-Bonded Particles for Higher Permeability
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Solution Overview
Problem
Conventional magnetic composite bodies experience low magnetic permeability and poor magnetic saturation characteristics due to the low filling factor of metal magnetic particles, which is exacerbated by the use of non-magnetic insulating films and varying oxide film thicknesses on metal magnetic particles.
Innovation Solution
A magnetic composite body is developed with metal magnetic particles and insulating fine particles, where oxide films are formed on the surface of the metal magnetic particles to bond adjacent particles, and insulating fine particles are used to improve the spacing between metal magnetic particles, thereby enhancing magnetic saturation characteristics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If insulating fine particles and insulating films are used to surround metal magnetic particles, then withstand voltage characteristics are improved, but filling factor of metal magnetic particles decreases
Solution Approach 1:
The patent changes the magnetic property parameter of the insulating film material from non-magnetic to ferromagnetic, transforming it from a magnetic isolation layer to a magnetic connection bridge. This allows the insulating film to maintain its electrical insulation function while restoring magnetic flux continuity, thereby resolving the contradiction between withstand voltage improvement and filling factor maintenance.
Solution Approach 2:
The patent employs composite material structure where ferromagnetic insulating films are combined with metal magnetic particles and resin. The ferromagnetic insulating film serves dual functions: electrical insulation and magnetic flux conduction, creating a composite structure that simultaneously achieves high withstand voltage and high filling factor with improved magnetic permeability.
2Reliability
If non-magnetic insulating films are used to cover metal magnetic particles, then dielectric breakdown resistance is improved, but magnetic permeability decreases
Solution Approach 1:
The patent fundamentally changes the magnetic parameter of the insulating film from non-magnetic to ferromagnetic. This parameter change enables the insulating film to conduct magnetic flux while maintaining electrical insulation, thereby resolving the contradiction between dielectric breakdown resistance and magnetic permeability.
Solution Approach 2:
The ferromagnetic insulating film acts as an intermediary substance between metal magnetic particles. It provides electrical insulation to prevent dielectric breakdown while simultaneously serving as a magnetic flux bridge to maintain high magnetic permeability, thus mediating between the two conflicting requirements.
3Strength
If oxide films of varying thickness are formed on metal magnetic particles, then bonding between particles is achieved, but uniform magnetic properties are compromised
Solution Approach 1:
The patent changes the material parameter of the insulating film from conventional non-magnetic materials (like TEOS or epoxy) to ferromagnetic materials. This parameter change ensures that even with varying thickness, the magnetic properties remain stable and uniform because ferromagnetic materials can conduct magnetic flux effectively regardless of layer thickness variations.
Solution Approach 2:
The use of ferromagnetic insulating films creates a homogeneous magnetic environment throughout the magnetic base body. The ferromagnetic material ensures uniform magnetic flux distribution and consistent magnetic properties across different regions, compensating for the non-uniformity introduced by varying film thickness.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The proposed magnetic composite body achieves improved magnetic saturation characteristics and higher magnetic permeability by optimizing the spacing and bonding of metal magnetic particles, allowing for increased rated current and better withstand voltage characteristics.
Implementation Method 1
an insulating first oxide film on a surface of the first metal magnetic particle, the first oxide film containing an oxide of an element constituting the first metal magnetic particle
Implementation Method 2
a plurality of metal magnetic particles including a first metal magnetic particle and a second metal magnetic particle adjacent to the first metal magnetic particle
Implementation Method 3
first fine particles in contact with the first and second metal magnetic particles, the first fine particles being insulating
Data Source
AI summary
A magnetic composite body contains a first metal magnetic particle and a second metal magnetic particle, and fine particles are in contact with the first and second metal magnetic particles. The fine particles are insulating and non-magnetic particles. A first oxide film is provided on the surface of the first metal magnetic particle, and a second oxide film is provided on the surface of the second metal magnetic particle. The fine particles may be provided on a surface of the first metal magnetic particles and separated from each other. The fine particles are insulating and non-magnetic and may include first fine particles. Optionally, first and second fine particles, or hydrophobically treated SiO2 particles, may be provided.